Process for manufacturing a rigid plastics tile with textured surface

ABSTRACT

Rigid composite impact resistant textured tiles having a pliable and essentially void-free plastics facing component and a rigid backing component, are prepared by a specific sequential operation.

United States Patent Roberts 1*Mar. 26, 1974 PROCESS FOR MANUFACTURING ARIGID [52] US. Cl 264/45, 156/78, 156/245, PLASTICS TILE WITH TEXTURED161/160, 161/161, 264/53, 264/250, 264/310 SURFACE [51] Int. Cl. B29d27/00 58 F Id fSe h 264 45, 53, 310, 250 [76] Inventor: Arthur H.Roberts, 12 Lynnwood 1 0 are Dr., Westbury, NY. 11590 56 R f C'tedNotice: The portion of the term of th1s 1 e erences I patent subsequentto Oct. 8, 1985, UNITED STATES PATENTS has been disclaimed. 2,948,6518/1960 Waag 264/45 X 2,976,577 3/1961 Gould 264/45 X [22] 197.12,977,639 4/1961 Barkhuff et 31.". 264/45 x 21 APPL 209 177 3,141,5957/1964 Edwards 264/45 X 3,187,069 6/1965 Pincus et a1. 264/45 RelatedUS. Application Data 3,390,214 6/1968 Woods .1 264/45 [60] Division f sNo 22 1 7 March 30, 197 3,623,931 11/1971 Van Hosen 264/45 X abandoned,which is a continuation of Ser. No.

526,605, Feb. 10, 1966, abandoned, which is a cdntinuatiomin-part ofSer. No. 455,764, May 14, 1965, Pat. No. 3,405,026, which is acontinuation-in-part of Ser. No. 475,989, July 30, 1965, Pat. No.3,414,456, which is a continuation-in-part of Ser. No. 523,778, Jan. 28,1966, Pat. No. 3,419,455, which is a continuation-in-part of Ser. No.525,667, Feb. 7,

1966, Pat. No. 3,420,729, said Ser. No. 455,764, said Ser. No, 475,989,said Ser. No. 5237778,. said Sen No. 525,667, Continuation-impart ofSer. 22,002.

Primary ExaminerDona1d E. Czaja Assistant ExaminerI-1. S. CockeramAttorney, Agent, or Firm-Laszlo Auer ABSTRACT Rigid composite impactvresistant textured tiles having a pliable and essentially void-freeplastics facing component and a' rigid backing component, are preparedby a specific sequential operation.

22 Claims, 25 Drawing Figures PATENTEDHARZB I974 3.800.016

SHEET 2 or 2 FIG. 3Zo.

.IiWl/(IIIAWA PROCESS FOR MANUFACTURING A RIGID PLASTICS TILE WITHTEXTURED SURFACE RELATED APPLICATIONS This application is a division ofapplication Ser. No. 22,1 17, filed Mar. 30, 1971, (now abandoned) whichis a continuation of application Ser. No. 526,605, filed Feb. 10, 1966(now abandoned) which, in turn, is a continuation-in-part ofapplications Ser. Nos: 445,764 filed May 14, 1956 (now US. Pat. No.3,405,026), 475,989 filed July 30, 1965 (now US. Pat. No. 3,414,456),523,778 filed Jan. 28, 1966 (now U.S. Pat. No. 3,419,455) and 525,667filed Feb. 7, 1966 (now U.S. Pat. No. 3,420,729), each of the lastfourmentioned applications being a continuation-in-part of applicationSer. No. 22,002, filed Apr. 13, 1960 (now abandoned).

This invention relates to novel, frigid, impact resistant tiles andmethods and means for their manufacture. In the prior art, tiles weremade of ceramic or plastics materials. These prior art articles ofmanufacture have the disadvantage of either being fragile or sensitiveto temperature changes.

An object of this invention is to provide tiles with improved propertiesand without the disadvantages of the prior art tiles. A further objectis to provide a process for producing tiles of plastics with improvedresistance to cold flow, chipping and breakage, and which is distinctlysuperior to prior art processes and the produc produced thereby.

The articles of manufacture of my parent application are rigid,three-dimensional and hollow. They comprise two components: (1) an outerlayer component, also called the shell and (2) an inner layer component,also called the flesh or rigidifier. In most of the cases varyingparallel cross sections of a single article show varying dimensions andshapes or configurations, indicating curved sidewalls and undercuts. Inother cases the cross sections may be identical, indicating box-shapedor cylindrical objects. In an alternative form of said parentapplications, the outer layer component and inner layer componentjointly form a cavity and this cavity is then filled with a reinforcingspine, such as a rigid plastics foam material. The outer layer componentis made of a flexibleplastics material, illustrated by plastisol andpolyethylene, whereas the inner layer component in the various parentapplications is ilustrated for instance by asphalt, plaster of paris anda composition comprising a filler which is bonded by the elastomersolids of a latex. In one of the parent applications the rigiditiercomponent is a rigid cellular plastics, as illustrated by rigidpolyurethane foams. In another one of the parent applications therigidifier component is a resinous composition comprising rigidpolyester resins or rigid epoxy resins.

The composite tiles of the instant invention are rigid and resistant toimpact. The tiles comprise a facing component and a backing component.The facing component has a front surface and a rear surface. The frontsurface of the facing component is textured. For this invention the termtextured includes raised and incised discontinuous patterns ofdecoration, such as embossed and carved designs, respectively. It alsoincludes discontinuously curved surfaces. The facing component is madeof a premolded pliable plastics and has preferably a wall thickness offrom about to about 250 mils. The term pliable means that the facingcomponent, when free of the backing component, is itself at leasttemporarily deformable by hand pressure. The backing component is arigid structural member that is in supporting relationship to the facingcomponent and rigidly maintains the latter in its preset and premoldedshape. The backing component is in intimate contact with the entire rearsurface of the facing component.

When discussing the measurements of the tile, it is useful to talk aboutits length, width and thickness. The tiles are preferably rectangular intheir dimensions of length and width. The measurements of length andwidth are not critical. If the dimensions in length and width arecomparatively larger, as for instance, when they are longer than a foot,the tile could well be called a panel. The measurements of length andwidth are more or less dictated by the manufacturing process or theintended end-use of the tile or panel. The thickness of the tiles andpanels preferably range from about oneeighth of an inch to about 2inches. These limits correspond to a thickness ranging from about toabout 2,000 mils.

In many instances it is advantageous to place an adhesive layer betweenthe facing and backing components in order to enhance their adhesion. Itcan also be of advantage to further support the backing component withan ancillary reinforcing element.

The materials suitable for individual components of the composite tilesof this invention will be discussed under their respective headingsfurther below.

The manufacturing procedures vary according to the selection of thefacing component and of the backing component. They will also-bediscussed further below.

All percentages, parts and proportions in this specification are byweight.

In some cases the total thickness of the tiles of this invention can bemade satisfactorily at one-sixteenth of an inch.

THE FACING COMPONENT Plastisols illustrate an eminently suitablematerial to form the facing component. They are dispersions of finelydivided polyvinyl resin powders in liquid organic plasticizers. Theresins contain vinyl chloride in-a polymerized state with or withoutother copolyrnerized monomers. They are polymerized to a degree wherethey have very low solubility at room temperature. Therefore, instead ofdissolving them, the plastisols contain the resins in a dispersed state;the dispersions are usually of creamy consistency at room temperatureand are always fluid to a certain degree. A great variety ofplasticizers can be used, such as dioctyl phthalate or dioctyl adipate.The plastisols usually contain stabilizers and may contain pigment, ifso desired. Formulations and application methods are described forinstance, in the following publications: (a) Geon Resin 121 in PlastisolCompounding. Service Bulletin PR-4, Revised Oct. 1958, B. F. GoodrichChemical Company, 24 Pages. (b) The Vanderbilt News. Vol. 26, No. 3,June 1960. R. T. Vanderbilt Company, Inc. Page 12. (c) Modern PlasticsEncyclopedia Issue for 1961, published in September 1960. Vinyl polymersand copolymers. Pages 129 to 132. Plastisol Molding, pages 765 to 771.(d) Modern Plastics Encyclopedia 1965, (issued. 1964). Vinyl Polymersand Copolymers, page 271. Plastisol Molding, page 690.

Recently a reactive vinyl plastisol system was introduced on the market.This consists of a mixture of a vinyl dispersion resin and a reactivemonomer. The former is dispersed in the latter. When heat is applied tothis system, also used to cause gelation an fusion, the reactive monomerpolymerizes and produces a more rigid product than previously producedwith conventional plastisols. Reactive acrylic monomers illustrateexamples of such reactive monomers.

When molding plastisols, the material is heated to a gelling temperatureand a gelled film or layer is formed which is very weak and cheesy, butwhich does not flow. Further heating is required to fuse the deposit,causing the resin to dissolve in the plasticizer and form a toughhomogeneous resinous mass in which the powdered resin and liquidplasticizer have formed a single uniform plane. The fusion transformsthe cheesy deposit or film to a tough leather-like homogeneous shell.

With regard'to temperatures required, these are well known in the art.They vary from composition to composition. They vary with time. Thereare, further, three types of temperatures involved: (1) oventemperature, (2) mold (die) tempearature and (3) temperature of theplastisol. Gelation temperature may be accomplished by heating theovenfrom 150 to 600 F. and usually is between a plastisol temperature of 150to 300 F. The necessary times vary with the temperature used. Fusion isaccomplished by heating the gelled layer in ovens from about 350 F. toabout 560 F. The achieved plastisol temperature for fusion shouldadvantageously range from about 350 to 450 F. The gelation temperatureand fusion tempeature depend on the formulation of the plastisols.Therefore some divergence from the above temperature ranges may occur ifspecial formulations are prepared.

The most useful molding methods for plastisol shells are illustrated by(a) slush molding, also called slush casting and (b) rotational molding,also called rota tional'casting. The expression casting is used becausethe plastisols are applied in fluid state and for this reason theoperation has similarity to metallurgical casting.

Whereas the casting by slush molding or rotational molding is preferredto form the facing component form plastisols, other methods known in theart may also be followed to achieve the same purpose. In a suitablealternative the polyvinyl resins may be compounded on plastic mills,calendered to a sheeting and embossed, to yield suitable facingcomponents.

Polyolefins, such as polyethylene and polypropylenene are otherillustrative examples for the production of the facing component of thisinvention. Polyethylene is made today of varying properties with the lowpressure and high pressure polymerization processes. It is supplied withvarying densities, molecular weights, flexibility and othercharacteristics. The types of polyethylene most suitable for thisinvention are pliable, flexible and show some degree of elasticity.Polyethyleneis preferred in this invention over polypropoylene since itis more easily formed into pliable and flexible facings. Polyethylenecopolymers, such as ethylenevinyl acetate and ethylene-ethyl acrylatecopolymers, offer improved flexibility and resilience. They arerubber-like and similar to elastomeric plastics. Polyallomers belong tothis class of materials, as they are copolymers of ethylene andpropylene.

The facing component may be formed of other materals such as vulcanizednatural and synthetic rubber. The facing components may be formedaccording to known procedures of rubber technology. Latex molding orcasting, utilizing plaster of paris molds, is an illustration.

Other suitable plastics materials, which can form the facing componet ofthis invention are illustrated by methyl methacrylate polymer, ethylcellulose, polycarbonates, polyurethane elastomers flexible epoxycompounds, flexible polyesters, amongst others. Some illustrativeexamples are given below:

EXAMPLE A. METHYL METHACRYLATE.

All percentages in this example and in this specification are weightpercentages. A mixture was prepared of 62.5 percent methyl methacrylatemonomer, 0.6 percent benzoyl peroxide, 2.1 percent white color pasteconcentrate, compatible with methyl methacrylate, 34.3 percentpolymethylmethacrylate, DuPonts Lucite 30, 0.5 percentdimethy-p-toluidine, totaling percent. The facings were prepared bycasting into suitable molds. The composition of this example polymerizesat room temperature. Heating to l00-l 20 F. accelerates polymerizationconsiderably. Latex molds can be used. Plaster and clay molds mayalso beused, if coated with gelatin, cellulose acetate, sodium silicate or tinfoil. Casting was carried out in a latex mold in three subsequent coatsand yielded a molded facing with acceptable flexibility and adequatemold surface reproduction. Plasticizers may be incorporated, if desired.l-larflex 340 of Harchem Division, Wallace &

Tiernan, Inc. is a suitable resinous-type, primary, non- EXAMPLE B.POLYCARBONATE Polycarbonates can be from organic solvent solutions.Polycarbonates dissolve,.with ease, e.g., in methylene chloride. Asolution was prepared from Lexan No. (General Electric Co.) powder toform a solution OF 83.3 percent polycarbonate in 16.7 percent methylenechloride, yielding 100 percent of the solution. As an example, thissolution can. be slush cast in latex molds, and air can be blown in toassist in volatilizing the solvent. The latex molds are standard incasting plaster of paris objects. The polycarbonate facing componentremains in the mold. It is very strong, flexible and durable, and caneasily be stripped from the mold. To reduce the effect of shrinkage,fillers may be incorporated. A ratio of equal weights of filler topolycarbonate is an illustrative example. The resulting facing componentis steill strong. Polycarbonate resins are marketed by General Electricunder the trade name of Lexan. Polycarbonates can be described aspolymeric combinations of bi-functional phenols or bis-phenols, linkedtogether through a carbonate linkage. they can also be blow molded andvacuum formed.

EXAMPLEC. FLEXIBLE EPOXY RESIN The proper composition has at least threeingredients. (l a low molecular weight epoxy resin of theepichlorhydrin-bisphenol Acondensation product type, like ShellChemicals Epon 828. (Epon is a registered trademark of Shell); (2) lowviscosity liquid aliphatic polyepoxides, like Epon Resin 871 whichimparts increased flexibility to Epon resin compositions; and (3) acuring agent, illustrated by diethylenetriamine andtriethylenetetramine, respectively known as DTA and TETA. Othercomparative items, known in the trade, may be replaced for thecommercial products mentioned. Fillers may be present as additionalingredients. A suitable additive to regulate viscosity is asubmicroscopic pyrogenic silica prepared in a hot gaseous environment,marketed by Cabot Corporation under the tradename of CAAB-O-Sil. Asatisfactory composition to obtain facings is 44.24 percent Epon Resin828, 44.25 percent Epon Resin 871, 2.65 percent of Cab-O- Sil and 8.85percent diethylene-triamine, totaling 100 percent. This composition setsat room temperature in about 5 hours and at 80 C. it sets in 2 hours.The composition may be varied according to principles known in the art.Facings can be molded in latex molds or other elastomer molds. These areactually multipieced plaster of paris molds externally reinforcing anentirely separate second flexible elastomer mold, having one opening forpouring in the composition to be molded and set. The rubber surface iscoated with a parting agent and the epoxy compostion is slush cast intothe molds. The slit mold here described is used to mold facings showingundercuts. Other molds and molding methods can also be used, dependingon the article to be manufactured. Epoxy plasticizers include epoxycomponds of fatty oils and their acids. Epoxy novolac resins andcycloaliphatic epoxies are other illustrative members of this group.Polyamids and acid anhydrides may also be used as curing agents.

EXAMPLE D. FLEXIBLE POLYESTERS Polyester resins are usually made in twosteps. In the first step a condensation reaction is carried out betweena dibasic acid and diol and this is then blended with a monomer. Maleicanhydride and fumaric acid are examples of the dibasic acids. Otherunsaturated acids could also be used, like itaconic. Phthalic anhydrideand isophthalic acid may be part components of the acids, to securedesired modifications. The useful glycols form a long list known in theart. Propylene glycol, ethylene glycol, diethylene glycol anddipropylene glycol are illustrative examples. Neopentyl glycol isanother exaniple. Styrene is most frequenty used as the crosslinkingmonomer. Vinyl toluene is another example. LAMINAC Polyester Resin EPX-1 26-3 is a flexible polyester resin containing styrene monomer. LAMI-NAC is a registered trademark of American Cyanamid. A composition wasprepared from LAMINAC Polyester Resin EPX-l26-3 92.6 percent, MEKperoxide 2.7 percent, Cobalt Naphthenate solution (6 percent Co) 0.27percent, LAMINAC Additive No. 10, 1.73 percent and Cab-O-Sil 2.7percent, totaling 100 percent. MEK peroxide is methylethyl ketoneperiode. LAMI- NAC Additive No. 10 is a petroleum wax compositiondispersed in styrene, for ease of incorportion into polyesters. Itimproves surface characteristics. The peroxide is the crosslinking agentand the cobalt assists the crosslinking. Flexible polyesters usuallycontain long chain acids or glycols. The gel time at room temperature isabout 10 minutes for this composition. The Cab- O-Sil assists inregulating the thickness of the deposit if slush casting is used formolding. Two or three coats can be slushed to obtain a desired facingthickness. The facing formation occurs at room tempearature more rigidpolyesters can be blended with the flexible one used in this example, tovary properties. Latex molds and those utilized for epoxy resins, may beused with polyesters.

EXAMPLE E. ISOCYANATE ELASTOMERS (URETI-IANE ELASTOMERS) Liquid urethanepolymers, such as DuPonts ADI- PRENE L- l 00, can be transformed intotough, rubbery solids by reaction of the isocyanate group with polyamineor polyol compounds. In addition, some materials which so not containactive hydrogens, such as the titanate esters, appear to catalyzecross-linking. ADI- PRENE L-lOO can be cured with diamines, or moisture(water), or polyols, or by catalysts, such as lead or cobaltnaphthanate, potassium acetate and titantate esters. Tetrabutyltitanateis an example of the esters. One of the popular polyamines is MOCA,which is 4,4- Methylene-bis-( 2-chloroaniline). A formulation isillustrated by 100 parts of ADIPRENE L-l00 and 12.5 parts of MOCA, whichgives a MOCA percentequivalent of 95.. Parts are by weight. Conditionswere: Mixing temperature: 212 F., cure temperature: 212 E, curing time:3 hours. LD-420 is a different type of liquid urethane elastomer, whichyields high quality vulcanizates when cured with MOCA. A respectiveformulation is illustrated by 100 weight parts of LD-420 (DuPont) and8.8 weight parts of MOCA. This is mixed and cured the same way asADIPRENE L-lOO, for the same length and cured the same way as ADIPRENEL- 100, for the same length of time. It is improved by aftercuring 1week at F. at 60 percent relative humidity. In making a facingrotational molding is recommended both for ADIPRENE L-l00 and forLD-420. A silicone mold release is advantageously used to assistseparation from the molds.

EXAMPLE lF. ETI-IYL CELLULOSE Ethylcellulose facing components can bemolded by various methods suitable for this plastics. Injection moldingand stamping preformed sheets are illustrative. The same applies tocellulose acetate and cellulose acetobutyrate. Where proper hot meltcompositions can be formulated, a combination of casting and hot meltmethods may also beused.

The preset molded facing components can be prepared by various moldingprocesses suitable for the respective selected plastics and known in theart. For illustrative purposes a few examples are given. Casting, suchas sluch casting or rotational casting: Plastisol, flexible polyester,flexible epoxy resins, methyl methacrylate, polycarbonates fromsolution, rubber from latex, etc. Injection molding; Plastisol,polycarbonates, ethylcellulose, polyethylene, cellulose acetate,cellulose acetobutyrate, etc. Hot melt process: Ethylcellulose,plastisol or other plasticized polyvinyl chloridecomposition,polyethylene, etc. Vacuum forming: Polyethylene,polycarbonates, polyallomers, etc.

Depending on the plastics material selected and the design of theobject, one-piece or multi-piece molds are used. The molding processalso influences the mold selection. Plastisol illustrates a facingcomponent forming material which permits the use of one-piece molds evenif the texture design has many undercuts in its shape.

The expression that the facing component materials are flexible, pliableand resilient is meant in a relative manner in comparison with thebacking component of the flexible facing component and improvesresistance to cold flow and heat distortion. The facing componentprotects the rigidifier backing component from fracture and improves itsresistance to impact. This mutual improving effect between the facingand backing components is unexpected and surprising, and the effectobtained could be described as synergistic. In many cases the tensilestrength of the composite tile shows improvement when comparedseparately with that of the facing or backing component. Theseobservations apply to facing components made of plastisols, flexiblepolyesters, flexible epoxy resins, polyethylene, polypropylene,polyallomers, polyurethane elastomers, rubber, polycarbonate,ethylcellulose, methyl methacrylate, amongst others. The degree of theabove discussed improvements may vary according to the selection of thefacing component forming material, its secondary compoundingingredients, thickness and shape of the facing component, selection andformulation of the material used for the backing component and itsthickness, amongst other factors.

According to a more recent type of molding method facing components canbe molded by rotational casting of powders. Polyethylene in powder formillustrates suitability for this method. The powder is rotated to obtainuniform distribution over the interior surface of the mold. The mold isthen heated to obtain the required molding temperature.

For the purposes of forming the facing component the thermoplasticplastics materials are preferred. These are illustrated by plastisolsand polyethylene. The reactive vinyl plastisol systems containingreactive acrylic monomers, discussed further above, are considered asthermoplastic for the purposes of this invention and are included in thepreferred group of plastics for forming the facing component of thetiles.

Latex moldingof the facing component, as discussed above, is describedin my prior application Ser. No. 475,989 now US. Pat. No. 3,414,456 andrelated data are in The Vanderbilt News, Vol, 27, No. 4, December 1961.This is a publication of the R. T. Vanderbilt Co. and deals with latexcompounding and molding.

THE BACKING COMPONENT The backing component of the composite tiles isapplied in a fluid state and is formed by a solidification processcarried out during the manufacturing process. The solidification may becaused by various factors. Plaster of paris solidifies by adjustment ofcombined crystal water. Asphalt is applied hot and solidifies bycooling. Latex compositions solidify by evaporation of water and in manycases additionally by vulcanization. Polyurethane foams, rigid polyesterresins and rigid epoxy resins solidify by polymerization and/orcondensation reactions. After the respective solidification process iscompleted the backing component becomes rigid and is suitable for itsrole to rigidify the pliable facing component of the composite tiles.

Plaster of paris is a calcium sulfate hemihydrate. It contains 1 mol ofwater per 2 mols of calcium sulfate in its structure. By the addition ofwater, plaster of paris is converted to a fluid composition and in timesolidifies to a solid product. Its setting time can'be accelerated byadding suitable accelerators known in the art and it can also beretarded by adding plaster retarders, such as glue, dextrin, etc. Myprior applications Ser. Nos. 22,002 (now abandoned) and 455,764 (now US.Pat. No. 3,405,026) discuss further details of the application ofplaster of paris as a rigidifier.

Asphalts vary in their properties depending on the source and locationof their derivation. They contain a large number of diversified chemicalcompounds in admixture, most of them being hydrocarbons by nature.Melting points, hardness, resistance to fracture, softening points,aging properties may vary to a great extent, amongst other properties.Based on available properties and the desired end-use it is not adifficult task to select the proper asphalt composition. Asphalt isapplied preferably from a molten and liquid state. It solidifies bycooling. My prior applications Ser. Nos. 22,002 now abandoned and455,764 now US. Pat. No. 3,405,026 contain data on the use of asphaltsas rigidifiers for specific purposes.

One of the favored backing components for the purposes of this inventionare rigid compositions comprising a filler bonded by the elastomersolids of a latex. lllustrative for suitable elastomer solids are latexsolids of natural rubber, or a copolymer comprising an acrylic ester andan acrylic acid, of a nitrile rubber, amongst others. Latex solidscomprising vinyl chloride and an acrylic acid, or vinyl chloride and anacrylic ester in a polymerized state, are other examples. My priorapplication Ser. No.'475,989 now U.S. Pat. No. 3,414,456 has moredetailed data on the various latices suitable to prepare rigidifiers. Anillustrative list of latices useful in the preparation of backingcomponents are: (1) Natural rubber latex, like centrifuged natural Hevealatex; (2) Gutta Percha latex; (3) Balata latex; (4) Styrenebutadienecopolymer latices of varying monomer ratios; (5) Polyisoprene latex; (6)Neoprene latex; (7) Butadiene-acrylonitrile latices of varying monomerratios; (8) Butyl rubber latex; (9) Polyvinyl chloride latices,plasticized, either internally or by plasticizer emulsion addition; (10)Polyvinyledene chloride latex; (l 1 Vinyl chloride-acrylic copolymerlatices; (l2) Ethylene-propylene copolymer latex, emulsified as acement, after polymerization is completed; (13) Acrylic copolymerlatices made of various monomer mixtures, amongst others.

Examples of commercial latex products available and the names underwhich they are marketed, are as follows:

Centrifuged natural rubber latex: UNITEX (Stein Hall). Polyisoprenelatex: Shell lsoprene Latex 700 (Shell Chemical Company).Styrene-Butadiene latex: Pliolite 5352 (Goodyear) with a 30:70 styreneto butadiene ratio and Polyco 2422 (Borden Chemical Co.) with a :10styrene to butadiene ratio. Neoprene (Polychloroprene) Latices: NeopreneLatex 571 and Neoprene Latex 400 (duPont). Butadiene- AcrylonitrileLatices: (a) Non-reactive copolymers: Hycar 1551 and 1561 (highacrylonitrile), Hycar 1562 (medium acrylonitrile) (Hycar is a registeredtrademark of B. F. Goodrich Chemical Company). (b) Reactive terpolymerscontaining in addition to butadiene and acrylonitrile a small quantityof an acrylic acid in a copolymerized state; Hycar 1571 (highacrylontrile) and Hycar 1572 (medium acrylonitrile). Polyvinyl chlorideLatices: Geon 151. (Geon is a registered trademark of B. F. GoodrichChemical Company). Polyvinyl chloride (P.V.C.) is not suitable as abinder as such and its latices have to be internally plasticized ormixed with a plasticizer emulsion or plasticizing elastomer latex. Latexplasticized polyvinyl chloride latex is illustrated by (icon 552 latex,which is an intermixture of a PVC latex and a latex of abutadieneacrylonitrile copolymer. Geon 576 illustrates an internallyplasticized PVC latex, produced by copolymerizing vinyl chloride withmethyl acrylate. A plasticizer plasticized PVC latex is illustrated by alatex containing in its solid content 100 parts of a copolymer of 80parts of vinyl chloride and parts of methyl acrylate and, in addition tosaid 100 parts, 35 parts of dioctyl phthalate in an emulsified state.Polyvinylidene chloride latices are rarely made as homopolymers.Examples of internally plasticized terpolymers are: (1) copolymer of 46parts of vinyl chloride, 27 parts of vinylidene chloride and 27 parts ofmethacrylic acid. (2) Copolymer of 46 parts of vinyl chloride, 27 partsof vinylidene chloride and 27 parts of methylhexyl acrylate. A product,which is an internally plasticized polyvinyl chloride and polyvinyledenechloride copolymer is Geon 450 X I67. Various other latices containingpolyvinyl chloride or polyvinylidene chloride are Geon 351, Geon 652,Dow Latex 700 (Dow Chemical), Pliolite 300 (Goodyear). Polyvinyl acetatehomopolymer is illustrated by Polyco l l7-H (Borden Chemical Company).

The expression acrylic polymer is considered for the purposes of thisinvention as ageneric term which includes acrylic copolymers, i.e.,polymers made of more than one acrylic monomer. An acrylic monomer is anacrylic type acid, its derivatives and substitution products of the acidand its derivatives. The term derivative includes esters and nitriles.

The term an acrylic type acid is a polymerizable alpha-beta unsaturatedmonovinylidene carboxylic acid, such as acrylic acid, methacrylic acid,ethacrylic acid, alpha-chloroacrylic acid, cinnamic acid, atropic acid,crotonic acid. Preferred are acrylic and methacrylic acids. Halogensubstituted acrylic acids are also advantageous.

The elastomers of this invention comprising an acrylic polymer areinsoluble in waterf Examples of nitrile derivatives are; acrylonitrileand methac rylonitrile.

Examples of ester-forming alcohols are the following: Alkyl alcohols,such as methyl, ethyl, n-propyl, isopropyl, Z-methyl pentanol,3,5,5,-trimethylhexyl, tertiary butyl, octadecenyl alcohol. Substitutedalkyl alcohols, such as chloroethyl, chlorobutyl, 2-methoxyethyl,2-butoxyethyl, 2-nitro-2-methyl propyl, oxoalcohol of an isobutylenedimer, alkoxyethyl; Alicyclic alcohols, such as cyclohexanol andmethylcyclohexanol; Aromatic alcohols, like phenols and araliphaticaochols, like benzyl alcohol; Heterocyclic alcohols, like furfuryl andtetrahydrofurfuryl alcohol. Preferred alcohols have one to 18 C atoms intheir aliphatic chain and the most commonly used ones have no more thaneight C atoms.

Acrylic acid homopolymers do not belong to this class, as they are watersoluble. Acrylic esters as homopolymers, or copolymerized alone, cannotbe crosslinked with ease. Acrylic nitriles as homopolymers yieldproducts that are too tough. Binary copolymers of acrylic acids withacrylic nitriles and binary copolymers of acrylic acids with acrylicesters can be crosslinked. One of the good copolymers is at leastternary and contains acrylic esters, nitriles and acids copolymerized.The acrylic acids in copolymers run between 2 and 15 percent of thetotal copolymer. Nitriles do not exceed, if used, 40 percent of thetotal, and 15 to 30 percent represents a satisfactory range. Acrylicester content of the copolymers may go as high as 95 to 98 percent, ifnitriles are absent. Where nitriles are present, the ester content mayrange from 40 to percent. Elastomer content can be varied by intermixingthe respective individual latices.

Prepolymerized elastomers may be emulsified in the presence or absenceor organic water-immiscible solvents, to form latex-type binders.Royalene P-3520 is an emulsified cement, made by U.S. Rubber, fromPrepolymerized ethylene-propylene copolymer. Neoprene cements can alsobe emulsified.

So Called carboxy-modified copolymers can be cross-linked many times bythe action of heat alone or by the addition of vulcanizing agents withor without application of heat. Hycar 1570 X 20 is a carboxymodifiedbutadiene/acrylonitrile latex suitable for coagulant dipping. It hashigh tensile strength, outstanding abrasion resistance and good oil andsolvent resistance. Its acrylonitrile content is characterized asmedium-high. Its stress-strain properties can be varied from thosecharacteristic of a rubber elastomer to those typical of a polyurethaneelastomer. vlt can be vulcanized by certain metal oxides or salts alone.Zinc oxide or sodium aluminate may be used as sole vulcanizing agent.

A standard sulfur/zinc oxide/accelerator system may be used forvulcanization also. Zinc oxide levels and pH changes can vary itsproperties, greatly. Calcium nitrate in methanol solution is arecommended coagulant.

A carboxy-modified butadiene-styrene polymer is illustrated by Good-rite2570 X 5. (Good-rite is a registered trademark of B. F. GoodrichChemical Co.) It has the ability to cure by theapplication of heatalone. Heat crosslinking can be catalyzed by the addition of oxalic acidor ammonium chloride, permitting lower curing temperatures. Of courseregular cures with conventional curing systems are also useful. A thirdcuring system is zinc oxide or sodium aluminate. These act upon thecarboxylic portion of the polymer. Sodium aluminate cures in 3 days atroom temperature-Zinc oxide performs similarly in the presence orabsence of sulfur.

A useful class of reactive acrylic copolymers is illustrated by Hycar2671, Hycar 2,600 X 92 and Hycar 2600 X l 13. Hycar 2671 is anionic andyields, upon airdrying at room temperature, properties which arevaluable for many applications. For curing, it requires temperatures offrom about 300 to about 325 F. Acid salts, like diammonium acidphosphate and ammonium chloride, lower the curing temperature.Crosslinking agents can be utilized, like glyoxal, butylene glycol,triazine resins, melamine-acrylic resins, etc. It has good resistance todiscoloration. Hycar 2,600 X 92 is a modification of Hycar 2,671 withimproved resistance to discoloration by light and heat, otherwise havingsimilar hardness or softness properties. It has greater modulus and lesselongation than 2,671 after 3 days roomtemperature drying. Oxalic acidcatalyizes its cures and lowers curing temperature. Zinc oxide is afavorable additive. Hycar 2,600 X l 13 is heat reactive and much softerthan 2,671 or 2,600 X 92. A cure cycle of 3-7 minutes at 300 F. issuitable. Oxalic acid or ammo- It will be realized that physicalstrength of the backing component will depend on the particular latexbinder applied, presence or absence of crosslinking or curing and thefiller combination used.

It is possible to vulcanize natural rubber particles in dispersed state,i.e., in latex form. Upon drying, such latex immediately forms strongvulcanized films. Such a latex was marketed under the trade name ofVultex with about 3033% NV. and in concentrated form under the tradename of Revultex with about 60-65% N.V. Such vulcanized or crosslinkedelastomer latices are also useful in this invention.

. The fillers used in the backing component with latices may be varied.Pigments, like titanium dioxide, lithopone, zinc sulfide, zinc oxide andothers used in emulsion paint formulations may be used. Extenderpigments and coarse fillers may also be used. Various types of clays orKaolins, calcium carbonate (natural or precipitated), such as whiting,and coarser materials, like flint (SiO can be utilized. A 60 mesh silicaillustrates the coarser materials. Talc and magnesium silicate, bariumsulfate, colored pigments, like iron oxides, ochres, etc. may be used.Addition of small quantities of fibrous materials to the fillers mayhelp to strengthen the backing layer portion of this invention. Asbestosfibers, short staple fiberglass may be mentioned as examples. Theillustrative example here below uses a combination of whiting, McNameeClay and flint (sil ica) in a satisfactory proportion.

Other examples of fillers are: shell flour, carbon black, diatomaceousearth, aliminum hydroxide, hydratedalumina, bauxite powder, magnesiumcarbonate, dolomite powder (calcium-magnesium carbonate), mica, etc. Forthe coarse particle size component vitreous rock of igneous origin maybe used. Portland cement forms with latices interesting compositions,while it binds part of its water content. With proper care portlandcement may be incorporated as part of the fillers.

Coarse fillers have greatly reduced surface area, compared with fineparticle size fillers. Therefore, a coarse filler can be loaded into alatex mix in comparatively high proportion, without requiring additionalbinder content. The coarse fillers help to reduce the danger of crackingduring drying and assist in decreasing shrinkage to a considerableextent.

When using clays as part of the filler, the soft clays, like McNameeclay, are more advantageous, than the hard clays, like Dixie clay.

The latex solids may have a varying relationship to the fillers. Apractical relationship is illustrated by a range from about 200 weightparts to about 2,000 weight parts of filler for each 100 weight parts ofthe elastomer binder. The latex solids are considered as the elastomerbinder of a particular latex. In my copending application Ser. No.475,989 now U.S. Pat. No. 3,414,456 numerous illustrative examples arelisted showing a range of from about 300 weight parts to about 1,000weight parts of filler per 100 weight parts of elastomer. Generallyspeaking, the water containing mixes forming the backing component ofthis type are highly loaded latex compositions, that is, they havecomparatively high filler content. The coarse particle size fillers inthe filler portion of the highly loaded latex type backing componentrange from about 40 percent to about 70 percent by weight of the saidfiller portion. It is preferred that the coarse particle size fillersexceed 50 percent of the total weight of the fillers used. The coarseparticle size fillers pass through a mesh screen and the fine particlesize fillers pass through a 200 mesh screen. A suitable filler portionof elastomer containing backing components is illustrated by about 10 to11 percent of clay, about 30 to 33 percent of whiting and about 56 to 60percent of 60 mesh silica.

A composition of matter suitable to form the elastomer bonded fillertype backing component comprises a filler component, an elastomer solidscomponent and water. The water ranges from about 10 percent to about 20percent by weight of the wet composition. The filler component ispresent in proportions ranging from about 300 weight parts to about1,500 weight parts for each 100 weight parts-of elastomer solids and thecoarse fillers are present in quantities ranging from about 40 percentto about percent of the total weight of the fillers. 60 mesh silicaillustrates a suitable coarse filler and it is advantageous if itsproportion in the total weight of the tiller portion is at least 50percent.

Example 1 illustrates a useful latex composition.

Example 1. l-levea Latex Composition for Backing Component.

Example 1. Hevea Latex Composition for Backing Component.

Dry Con- Wet tent in Dry Weight wet weight, Weight PART B %/WeightNatural centrifuged latex,

62.5% NV. 1175 7.34 8.60 Aqueous KOH solution 0.36 0.04 0.05 2571Aqueous Darvan 7 solution 0.07 0.02 0.02 6591 Aqueous dispersion ofAgerite Spar 0.11 0.07 0.08 Setsit 5| acceleration 100% 0.1 l 0.11 0.13

Subtotal for part B 12.40 7.58 8.88

PART C Mix Parts A B Subtotal 55.90 41.24 48.32

PART D Silica 60 mesh 44.10 44.10 51.68

Total 100.00 I 85.34 100.00

Parts A and B are first prepared separately and then they are mixed.Part D is added last.

In another embodiment of this invention the backing component is a rigidcellular plastics. This may have open or closed cell structures. Theyareillustrated by rigid foams of polyurethanes, polystyrene, silicones,epoxy resins, polyvinyl chloride, phenolic resins, cellulose acetate,acrylic compositions, polyesters, urea resins, asphalts, amongst others.Syntactic foams represent a special group. Rigid plastics foams are wellknown in the art and are discussed by T. H. Ferrigno in Rigid PlasticsFoams, Reinhold Publishing Corp., 1963. The rigid plastics foams are notequally suitable for the instant invention. Thermosetting plastics foamsare preferred. The most preferred rigid plastics foam formers are therigid polyurethane foam compositions. The next preferred foam formersarethe'rigid epoxy the polyester polyols supplying additionalOR-grouping for the foaming and polyurethane forming reaction. In thisH-seriesthe R-component containsthe fluorocarbon blowing agent, thecatalyst, such as N-ethyl morpholine and dibutyltin dilaurate and mayalso contain all or part of the surface active agents, such as thesili-. cones. The suitable fluoro-carbon' is illustrated by Freon No.1.1, which is trichloro-fluoromethane, having a boiling point of about74.7 F. The H-series of Nopcofoam compounds have a fast curing cycle.With formulation changes the curing speed and the pcf (pounds per cubicfeet) of the resulting foam may be varied.

. The same .applies to the start of the rise and rise time resincompositions. Low curing temperatures and fast foam setting rates are anadvantage. The setting rate should not be so fast as to prevent adequatedistribution of the foaming composition over the entire rear surface ofthe facing component. My prior patent application Ser. N0. 523,778 filedJan 28, 1966 (now U.S. Pat. No. 3,419,455) discusses rigid foamcompositions and their chemistry in detail.

Rigid polyurethane foam layers can be prepared according to thisinvention by any one of the three major methods: (1) prepolymer method,(2) quasiprepolymer method and (3) the one-shot method. The quasiprepolymer method is preferred. The application by poured-in-place orfoamed-in-place method is satisfactory. ln the quasi-prepolymer methodthe diisocyanates are prereacted with a portion of the chemicallyequivalent quantity of polyols or polyetheralcohols leaving a desiredexcess reactive NCO groups free and available for a second. stagereaction.

Quasi-prepolymer two-package systems are marketed by various supplierswith varying qualities. As illustration Nopcofoam l-l-102N and NopcofoamH- lO3N systems are mentioned, supplied by Nopco Chemical Company. Thecomponents are marketed as T-component and R-component. The T-componentis the quasi-prepolymer formed by the diisocyanate and a polyetherpolyol. It has reactive -NCO groups. It supplies the isocyanate radicalsfor the foaming reaction. The T-component may also contain surfaceactive agents, such as silicones. The R-component contains of thefoaming. Nopcofoam H-l02N supplies a rigid foam close to 2 pcf.

The foaming instructions are as follows for Nopcofoam H-lO2N: Thetemperature of both components should not be higher than about 75 F. Themixing ratio is about 52 percent R and 48 percent T, by weight. TheR-component I is poured into the T- component in the proper weightratio. This is followed by mixing with a high speed drill motor, havinga minimum RPM of 1800, using proper mixing blades, such as an impellertype. Mixturebecomes creamy white and volume increase is noticed inabout 25 to 30 seconds. The mold containing the facing component, or thefacing component acting as a mold, may advantageously be preheated to toF. This is advantageous particularly where the foam has to fill areas ofsmall cross-section. The higher the temperature the more rapid thefoaming action. The foam cures at room temperature in about 24 hours.

The foaming instructions for Nopcofoam H-103N are similar to those ofH-l02N with regard to temperature, mixing, mixing time, and curing.However, the mixing proportions of the components are about 50 percentR-component and about 50 percent T-component, by weight. The averagecore density is 2.6 pcf; the K Factor, Aged (BTU/hr/sq.ft/F./in.thick)is 0.120; maximum recommended service temperature is 180F.

Carbon dioxide blown rigid foams can also be prepared from prepolymersor quasi-prepolymers.

One of the advantages of rigid polyurethane foams and rigid epoxy resinfoams for the purposes of this invention is that they can be cured atroom temperature or at comparatively low elevated temperatures.

According to still another embodiment of this invention the backingcomponent comprises rigid resinous compositions. These are either rigidpolyester resin compositions or rigid epoxy resin compositions. Both ofthese types can be cured to a thermoset stage at low temperatures, suchas at room temperature.

Copending application Ser. No. 525,667 (now US. Pat. No. 3,420,729),contains detailed discussion of rigid polyester resins and rigid epoxyresins. Polyester resins are made in two steps. In the first step acondensation and esterification reaction occurs between a dibasic acidand a diol. In the second step the condensation product is blended witha reactive monomer, such as a vinyl monomer. The dibasic acids can besaturated and unsaturated. The saturated ones are illustrated byphthalic anhydride and isophthalic acid. These aromatic dibasic acidsbehave like saturated acids and this is why they are so considered inthe chemistry of polyesters. Maleic anhydride, fumaric acid and itaconicacid are examples of the unsaturated dibasic acids. Propylene glycol,ethylene glycol, diethylene glycol, dipropylene glycol, amongst others,are examples of suitable diols. Styrene and vinyl toluene are examplesof the crosslinking vinyl monomer. The monomer content ranges from about25 percent to about 50 percent. It is customary in the trade to considerthe modulus of elasticity in flexure, expressed in psi, as an indicatorwhether a polyester is rigid or flexible. The respective values are:Semi-rigid to rigid polyesters 3 to 6 X 10 psi, semi-flexiblepolyesters-l to 3 X psi and flexible polyesters less than 1 X 10 psi.For flexible polyesters many times the flexural strength and flexuralmodulus are lower than what could be measured on conventional testingmachines. Elongation at break in percents ranges between 1 and 2 forrigid polyesters and may range as high as 75 to 200(for flexiblepolyesters. Examples 2 and 3 illustrate compositions suitable to formrigid polyesters for the backing component of the tiles. The latter oneis suitable for fiberglass reinforcement.

EXAMPLE 2: RIGID POLYESTER FOR BACKING COMPONENT.

A rigid polyester slush casting composition is prepared by mixing 41.34percent of LAMINAC Polyester Resin 4128, 0.10 percent cobalt naphthenate(6 percent Co), 41.34 percent of 325 mesh silica (flint), 16.53 percentof 60 mesh silica (flint), and 0.69 percent MEK peroxide, totaling 100percent. The ingredicuts are mixed in the order of listing. The settingtime of this filled polyester composition can be varied by changing theproportions of the catalyst (MEK peroxide) and cobalt metal content. Thepolyester resin used in this example gels at room temperature in absenceof fillers in time intervals ranging from about 10 minutes with 1percent catalyst and 0.3 percent cobalt naphthenate (6 percent metalcontent), to about 180 minutes with 0.5 percent catalyst and absence ofcobalt naphthenate. In these gelling tests the MEK peroxide is appliedas catalyst in a 60 percent solution. The setting time of the filledcomposition of this example may be varied from about 4 minutes to aboutseveral hours at room temperature.

EXAMPLE 3: RIGID POLYESTER COMPOSITION FOR BACKING COMPONENT, SUITABLEWITH FIBERGLASS REINFORCEMENT.

A composition suitable for use with fiberglass reinforcement has thefollowing weight parts: LAMINAC Polyester Resin 4128 parts, cobaltnaphthenate (6 percent metal content) 0.2 parts, 325 mesh silica 100parts and MEK peroxide 1 part, totaling 201.2 parts. This compositionsets in about /& hour. By varying the quantities and proportions of thecatalyst and accelerator the speed of setting can be changed andregulated. Increased ambient temperature accelerates setting time.

Epoxy resins are characterized by the presence of epoxy groupings. Theyare well known in the art. Reference is made to Modern PlasticsEncyclopedia 1966, referred to above, pages to 169. One of thecommercially available types is made by condensation of bisphenol A withepichlorhydrin. Generally 2 mols of.

epichlorhydrin are reacted with 1 mol of bisphenol A. Polymerization mayoccur during the condensation reaction in varying degree. All of theseresins have epoxide groupings in the two end positions in a linearlywritten formula. The polymerized center positions show,

ether linkages and hydroxyl groupings, both formed by the epoxy groupingof the epichlorhydrin. If we consider the number of the linkagesconverted to etherhydroxyl groupings as n, one can visualize that n canbe equal to zero or more. The resins containing n O l are liquid and arepreferred for the purposes of this invention. The types where n ishigher than 1 become gradually more solid and brittle and are moresuitable for esterification reactions, for instance, with fatty acidsfor coating material purposes. A few EPON resins are listed here forillustrative purposes. EPON is a registered trademark of Shell ChemicalCompany. EPON Resin 828 is designed in theory to give n 0, but inpractice its n content is between 0 and 1. Its epoxide equivalent is toI92. EPON Resin 830 is similar to EPON Resin 828, but its n is slightlynearer to 1 than with the 828 type. This indicates the presence of somehigher homologues. Its epoxide equivalent is to 210. EPON Resin 834 isformulated in theory to have n 1, but in practice its n is between 1 and2. This is also indicated by the epoxide equivalent of 230 to 280 forthis resin. All 3 of these resins are liquid at room temperature.

Another type of epoxy resins is the group of lowviscosity, liquid,aliphatic polyepoxides. They are prepared by'the oxidation of olefinswith peracetic acid. Other examples of epoxy resins are cycloaliphaticepoxy resins and epoxidized fatty oils and fatty acid esters. EPON Resin871 is an illustration of liquid aliphatic polyepoxides with an epoxideequivalent of 390 to 470. It is compatible with EPON Resin 828 in allproportions and is suitable to increase the flexibility of the latter.The list herein given is illustrative and does not limit the scope ofsuitable epoxy resins.

The selection of a curing agent or hardener for epoxy resins depends onthe application. Factors considered in selection of the hardenerinclude: (1) viscosity; (2) pot life; (3) curing cycle; (4) end-useproperty requirements; and (5) environmental conditions expected in theend-use. The curing agents fall into the broad categories of (a) amines,(b) acids and anhydrides and (c) catalysts and latent hardeners.Suitable curing agents include DTA (diethylenetriamine, also calledDETA). AEP (N-aminoethylpiperazine), TETA (triethylenetetramine, NMA(NADIC Methyl Anhydride), AA (adipic anhydride), DDSA (dodecenylsuccinicanhydride). Catalysts include borontrifluoridemonoethylamine,dicyandiamide and benzyldimethylamine.

Flexibility and rigidity is regulated, for example, by the percentualproportion of the bisphenol-A comprising rigid epoxy resins and of theflexible liquid aliphatic poly-epoxide. Epoxidized fatty acid esters mayalso be used as flexibilizing additives.

Epoxy plasticizers include epoxy compounds of fatty oils and theiracids. Epoxy novolac resins and cycloaliphatic epoxies are otherillustrative members of the epoxy resin group. Polyamids and acidanhydrides may also be used as curing agents.

A limit of 10 percent elongation at break is a reasonable top limit tocharacterize rigid epoxy resins. Higher elongation values indicateflexibility to a greater or lesser degree, and characterize flexibleepoxy resins.

Example 4 illustrates a rigid epoxy composition for the backingcomponent.

Example 4: Epoxy Resin composition for backing component.

A suitable composition has the following weight parts: EPON Resin 828100 parts, Epoxide No. 7 (Procter & Gamble) parts, 325 mesh silica 100parts, 60 mesh silica 100 parts, diethylenetriamine 10 parts, totaling315 parts. A small quantity of Cab-O-Sil can be added to regulateviscosity and drainage time. This additive increases viscosity anddecreases drainage time on vertical surfaces. The composition of thisexample is suitable for fiberglass reinforced applications.

The backing component may advantageously be reinforced by fibrousmaterials. Fiberglass illustrates such fibrous materials. Fiberglassreinforcements are supplied as continuous strands, fabrics, mats,chopped strands, and other forms. Other useful fibrous reinforcementsmay include sisal, cotton, jute, asbestos, synthetic fibers, andmetallic fibers, amongst others. Suitable aftertreatment of fiberglassfibers, prior to their application in the instant invention, may beadvantageous to improve their processing characteristics, includingtheir ease to be wetted by resins. Treatment with chromium compounds andwith silanes (silicones) illustrates after-treatment methods.

Fiberglass is a suitable illustration for fibrous reinforcement. It canbe applied by a number of processes. Suitable application methods are,for instance, the ones known as hand lay-up method, spray-up method andcentrifugal casting method. For each particular method the glass fibersare selected in a proper form. For instance, continuous roving can beused with spray-up and centrifugal casting, and mats, fabrics, wovenrovings can be used for hand lay-up. In one application method choppedstrands and the polyester composition are sprayed simultaneously from aspecial gun, depositing both the fiberglass and the polyester resincomposition in proper proportion on the interior surface of the outershell component, that is the facing component. In another applicationmethod the chopped strands are preimpregnated with the resinouscomposition and jointly applied. This requires a dispersion of thechopped, strands in the resinous composition. In the hand lay-up methodthe polyester composition is applied first by brushing or spraying andthe fiberglass can then be applied as a mat by hand and rolled over by aspecial roller to remove air pockets. This is followed by another coatof the polyester composition. In still another method the choppedstrands are distributed by a suitable method over the surface of thefreshly applied resinous composition, for instance, by the aid of a blowgun and this step is followed by an additional application of thepolyester composition.

- cial circumstances require such changes.

Whereas unfilled rigid polyester and epoxy resins can be used to formthe backing component according to this invention, filled compositionsare preferred.

The fillers reduce shrinkage during curing and have other additionaladvantages. Silica (flint) illustrates a suitable filler. 325 and 60mesh qualities are presented in the illustrative examples. When 60 meshsilica is used, the composition may require the use of a special type ofspray gun, on account of the large particle size of some of the fillerparticles.

The backing components here above listed are not equivalent. The mostpreferred backing components are the reinforced rigid polyesters,followed by the reinforced rigid epoxy resins. In most cases they do notrequire ancillary reinforcing elements. The others follow in the orderof declining preference, as follows: rigid non-reinforced polyesters,rigid non-reinforced epoxy resins, compositions containing fillers boundby elastorner latex solids, asphalt and plaster of paris. The latex typecompositions require evaporation of water during manufacturing. Asphaltsare frequently sensitive to heat and require the additional use of anancillary reinforcing element. The plaster of paris containing tilesrequire in many cases an ancillary reinforcing element to improve theirresistance to impact.

The above listing of suitable backing components of the composite tilesof this invention are intended for illustrative purposes and do notintend to limit the herein claimed invention.

IMPROVING ADI-IESION BETWEEN THE FACING AND BACKING COMPONENTS.

In many instances it is advantageous to apply an adhesive as anintermediate layer between the facing and backing components. This isparticularly true when the facing component is derived from plastisoland the backing component comprises a rigid polyester.

Neoprene adhesive illustrates a suitable adhesive. A neoprene cement isdiluted, for example, with methylethyl ketone in the proportion of 20percent cement and percent solvent. This solution may be applied byslush casting or spraying, depending on the conditions of themanufacturing method used. For individual purposes suitable adhesivesmay be selected from the group of resorcinol adhesives, rubberemulsions, rubber solutions (cements), epoxy resins, special polyesterresins, latex adhesives, latex modified cements, hot asphalt adhesives,amongst others.

Other adhesives suitable for individual purposes are: (1) Solutions ofVINYLITE Resin VAGI-l in solvents, as in methylethyl ketone, or inmixtures of toluene and methylethyl ketone. This is a copolymer of vinylacetate, vinyl chloride and vinyl alcohol, and is compatible with alkydresins and polyesters. (2) Polyurethane adhesives of the 2 part and 1part systems. (3) An adhesive containing vinyl resins, methylethylketone, dioctyl phthalate and methylene-bis(4-phenyl isocyanate). (4)Nitrile rubber adhesives. (5) Nitrile-phenolic adhesives as discussed onPage 490, Col. 2, Par. 6 of Handbook of Adhesives, by Irving Skeist,Reinhold Publishing Corp., 1962/64. See also pages 236 to 241 of samepublication.

According to one embodiment of this invention, improved adhesion can beachieved by the application of a joint contact resin ingredient beingsimultaneously present in the facing component and the backingcomponent. This contact resin is compatible with the composition of bothcomponents and its simultaneous presence promotes the adhesion of thetwo components, thereby eliminating the need for a special adhesivelayer placed between them. A peracetic epoxy resin is a suitableillustration. BAKELITE Epoxy Resin ERL- 4289 isbis(4,4-epoxy-6methylcyclohexylmethyl) adipate. In one step 20 phr(parts per hundred resin) of this peracetic epoxy resin is incorporatedinto the plastisol composition and borontrifluoridemonoethylamine isadded thereto in a proportion of 2 percent additive based on the weightof the epoxy resin. This plastisol compound is then molded at about 275F. for a time sufficient to gel, but not to fuse the plastisol. The moldis opened and the rigid polyester forming composition is applied. Thepolyester composition contains about 10 percent of the peracetic epoxyresin ERL-4289 based on the weight of the polyester resin. The curing isthen continued to complete the fusion of the plastisol component and thesetting and polymerization of the rigid polyester containing backingcomponent. This process results in a satisfactory adhesion between thetwo components, however, it is not suitable for facings which haveundercuts that make removal from the mold difficult afterrigidification.

ANCILLARY REINFORCING ELEMENTS With the manufactured composite tiles ofthis invention it is in many cases useful and desirable to apply anancillaryreinforcing element as an additional layer behind the backingcomponent. Such ancillary reinforcing elements improve the resistance ofthe composite tile to strong stresses, pressures or impact. They assistthe rigidifying action of the backing component and toughen themanufactured composite tile. The ancillary reinforcing element may be ofmetal, paper chipboard, cardboard, cement board, plaster board,Masonite, or of a synthetic resin layer, amongst other suitablematerials. The element may be continuously or discontinuously applied tothe rear surface of the backing component. When it is to be continuousand is liquid at the time of application, it may be applied by casting,such as slush casting and rotational casting. Low melting point metalalloys, used as ancillary reinforcing elements, maybe applied bycasting. The same applies to the suitable synthetic resin compositions,illustrated by flexible polyester resins and essentially flexible epoxyresins. Rigid plastics foams may also be utilized as ancillaryreinforcing elements. These are illustrated by rigid polyurethane foams.The foam can form either a layer on the entire rear surface of thebacking component or fill only joint cavities formed by the facing andbacking components in the position of textured areas. The foams areadvantageously applied by the foam-inplace method, wherever otherconditions permit such an application.

Some of the favored ancillary reinforcing elements of this invention arethe flexible epoxy resins and flexible polyester resins. The flexibleepoxy resins are preferred for this purpose. They can be applied in manycases by slush casting and they set overnight at room temperature to asufficient degree so that the tiles can be handled. Completion of thepolymerization to the desired degree is achieved in an additional fewdays during room temperature storage. The epoxy layers are very tough.Example 5 illustrates a flexible epoxy resin composition suitable asancillary reinforcing element.

EXAMPLE 5: EPOXY RESIN COMPOSITION FOR ANCILLARY REINFORCING ELEMENTS.

A flexible epoxy resin composition is prepared of the followingingredients: 15.05 percent EPON Resin 871, 15.05 percent EPON Resin 828,6.15 percent Epoxide No. 7 (an epoxy plasticizer of Procter & Gamble),30.20 percent of 325 mesh grade silica, 30.20 percent of 60 mesh gradesilica, 3.00 percent of diethylenetriamine (DTA) and 0.35 percent ofCab-O-Sil, totaling 100 percent. The nature of some of the ingredientsaredescribed further above in this specification. The Cab-O-Silregulates viscosity, flow and stoppage of flow. EPON Resin 871 comprisesunsubstituted 2,3- epoxyalkyl esters of mixtures of dimer and trimerfatty acids having 12-30 carbon atoms.

An illustration of desirable thickness for the resinous ancillaryreinforcing elements is from about 15 /2 mils to about 250 mils. Many ofthe resinous compositions can be applied by spraying. When the backingcomponent is a resinous material, useful proportions between thethicknesses of the resinous backing component andof the resinousancillary reinforcing element are between a proportion of 1:1 and aporportion of 1:3. These proportions and thickness ranges areillustrative and are not given to limit the scope of the claimedinvention.

When the ancillary reinforcing element is a prefabricated board orsheeting, the application of an adhesive may be required to achieveproper adhesion between said board or sheeting and the rear surface ofthe backing component.

A fiberglass reinforced rigid polyester composition 1 may also be usedas an ancillary reinforcing element.

METHODS OF MANUFACTURE AND DRAWINGS The tiles of this invention can bemanufactured by various methods and process steps. Without limiting thescope of the invention herein claimed, four processes will be listed forthe purposes of illustration.

Method 1: A facing component is premolded. It has a front surface, aback surface and sidewalls. The composition forming the backingcomponent is deposited in a liquid state in the cavity of the facingcomponent which has sidewalls. Casting, such as slush, casting, is asuitable method of deposition. No supporting mold is required during theapplication and solidification of the composition forming the backingcomponent. FIG. 11 illustrates a tile made by this method.

Method 2: In this method a tile press, suitable for making ceramictiles, is used. The facing component and the backing component areformed in the same equipment in subsequent steps. FIG.'4 illustrates theequipment for this process. This method is applicable to the productionof tiles with facing components prepared from prefabricated sheetings,among others.

Method 3: The facing component in this method is prepared with amarginal area not covered by the backing component. The facing is placedin a holder, illustrated by FIG. 7 and FIG. 8. The marginal area of thepreformed facing component assists in holding the latter in positionduring the application of the composition forming the backing component.

Method 4: This method is related to Methods 1 and 3. The facingcomponent has sidewalls in addition to its front surface and backsurface. With its sidewalls this type of facing component forms acavity. The facing component is premolded in a holder illustrated byFIG. 8A. The holder also permits keeping the facing component in asupporting mold during the formation of the backing component. The moldmay be the same as used to premold the facing component.

In contrast to the products of my parent applications the tiles of theinstant invention are substantially flat objects. Their predominantdimensions are length and width and they have a relatively low height orthickness. For this reason the sidewalls of the facing component,whenever such sidewalls exist, are low. The preferred thickness of thetiles is from about A inch to about 1 inch. In some. instances thethickness may be as low as one-eighth of an inch and as high as about 2inches.

Methods of molding the compositions forming the facing component havebeen discussed further above. Depending on the composition selected themethods of premolding may vary greatly. Slush casting, calendering,vacuum forming are some of the methods which can be utilized. Thecompositions forming the backing componentare advantageously appliedfrom a liquid state. They can be applied by pouring, slushing, spraying,knife coating, troweling, amongst others. If the composition forming thebacking component is thermoplastic, the application may be from solidstate, such as from powder, and pressure combined with elevatedtemperatures may be used for the formation.

In forming the backing component, a retaining sidewall is used. This canbe formed bythe facing component itself and remain a part of the tile soformed, or it may be created by a mold that is removable after thecomposition forming the rigidifying backing component sets to a solid.FIGS. 1, 2 and 3 illustrate the crosssectional views of molds suitableto form facing components. They are electroformed 'molds, and aresuitable to form plastisol into tile or panel shapes. FIG. 1 shows,additionally, a facing component 26 formed in the mold 25. The frontsurface of the facing components formed in these molds are textured. Thefacing component produced in the mold of FIG. 1 is suitable for Method1, described above. After the facing component is removed from the moldthe backing component may be formed in the facing component havingsidewalls. The composition forming the backing component by this methodis applied from a liquid state.

FIG. 4 illustrates the cross-sectional view of a tile press and tiledie. The die is mounted in the special tile press. The press may beoperated by hydraulic pressure or other means. The sides 29 of the dieare fastened to the press. The bottom platen 30 of the die rests on thebottom plate 48 of the die 49 which in turn rests on the bed of thepress. The top platen 28 of the die is attached to a shaft 27. Thisshaft 27 is attached to the drive of the press and is able to move upand down. The material to be molded into the facing component is placedon the top surface of the bottom platen 30. After the material to bemolded is in place, the top platen 28 is lowered by means of the shaft27, thus applying pressure on the material. This pressure compacts orpresses the material into its desired shape, and forms the premoldedfacing component 26. The die may be heated, if so desired. Depending onthe pressures and molding temperatures applied, the material to bemolded may be a liquid, like plastisol, may be a powder, likepolyethylene, may be granules or be a prefabricated sheeting. After themolding is completed, the top platen is withdrawn upward and the bottomplaten is pushed up by the aid of shaft 31 until the facing component 26is free of the sides 29 of the die. The facing component is thenstripped from the bottom platen. In an alternative of this method thetop platen 28 is withdrawn after molding of the facing component iscompleted; the composition forming the backing component is then appliedin a liquid or powdery state to the rear surface of the premolded facingcomponent while the latter is still in its original position. The topplaten 28 then descends again and forms the backing component behind therear surface of the facing component. Temperatures and pressures areadjusted to yield the desired results with the particular compositionselected to form the backing component. FIG. 4 shows the so formedbacking component 32. If so desired, an adhesive can be sprayed on orapplied by a suitable means to the rear surface of the premolded facingcomponent, prior to applying thereto the composition forming the backingcomponent. Neoprene adhesive is a suitable illustration if the facingcomponent is made of plastisol and the backing component is made of arigid polyester. After the setting of the backing component is completedthe upper platen is raised and the lower platen is pushed up tofacilitate removal of the tile from the die.

FIG. 5 is the cross-section of the tile removed from the die of FIG. 4.26 is the facing component and 32 is the backing component.

FIG. 6, is the cross-section of a facing component prepared in a diesimilar to that of FIG. 4. 26 is the facing component. 33 is anextension portion of the facing component usefulin the methodillustrated by FIGS. 7, 8 and 9. This extension portion is removed afterthe backing component has been applied.

FIG. 7 is a planar view of a holder frame, showing sides 35 holding thefacing component 26. The sides are held in place by fasteners 36, suchas nuts and bolts.

FIG. 8 is a cross-sectional view of the holder illustrated by FIG. 7holding the facing component illustrated by FIG. 6. 35 designates thefour sidewalls of the holder. 35 reaches over the extensions 33 of FIG.6 and holds the facing component in position. 26 is the facingcomponent. 36 designates the fasteners of the holder. 34 is a bottomrest for the facing component and is a part of the equipment. The sides35 form a type of a wall permitting the application of the compositionforming the backing component by slush casting. If an ancillaryreinforcing element is to be applied, which can be slush cast, thecomposition forming the ancillary reinforcing element can also beapplied by using the equipment illustrated by FIG. 8. There are fourholder sides 35 in this equipment and the sides can be made, forinstance, of wood or metal. 32a is the same as in FIG. 9.

FIG. 9 illustrates a cross-sectional view of the facing and backingproduced in the holder equipment of FIG. 8. 26 is the facing component.33 is the same as in FIG. 6. It is not rigidified by the backingcomponent and is removed by trimming. 32a is the backing componentapplied in a fluid state. Section line a is where the trimming isperformed. Rigid polyester and rigid epoxy resin compositions areexamples of suitable materials for forming the backing component by thismethod.

FIG. is the cross-section of a tile produced in the equipmentillustrated by FIGS. 7 and 8. 32a is the backing component formed from afluid state. 26 is the facing component. The non-backed portions of thefacing have been removed by trimming. 37 is an ancillary reinforcingelement formed from fluid state in the equipment of FIGS. 7 and 8. Aflexible epoxy resin composition is an example for such element. Therear surface of the tile may be ground to a flat surface. Thecomposition forming the ancillary reinforcing element is poured into thecavity formed by the holder sidewalls and the rear surface of thebacking component.

FIG. 8A is the cross-section of a multi-piece mold with clamps 44. Themold sides 45 are removable. There are four such sides. 46 is the moldbottom. As an alternative, the mold may be a two-piece mold in whichcase there 'is a split in the center area of 46. Facing component 26 isslush cast and has sidewalls in addition to its facing portion. 32a is aslush cast backing component. FIG. 24 shows a tile which can be made ina similar equipment to that shown in FIG. 8A. The application of a moldrelease agent on the mold enhances ease of removal of the articlesproduced therein. A silicone mold release illustrates such a product.This figure illustrates equipment suitable for carrying out Method 4 ofthe manufacturing process discussed further above. It may be stated,that various alternative steps are available. In one such alternative,the facing component is made by pouring and therefore does not formsidewalls. The same applies to the composition forming the backingcomponent. If an ancillary reinforcing element is to be formed from acomposition being in a fluid state, the said element can also be formedin the equipment of this figure.

FIG. 11 is the cross-section of a tile produced with the facingcomponent premolded in the mold of FIG. 1. The facing is first formed inthe mold of FIG. 1. Then the composition forming the backing componentis ap plied from fluid state by, for instance, slush casting. Thebacking component is formed in the facing component without the use of asupporting mold. This is made possible by the shape of the facingcomponent which has low sidewalls. 26 is the facing component and 32a isthe backing component formed from a fluid composition. Section 14" showsthe position of cut made for FIG. 14.

FIG. 12 is the cross-sectional view of a tile similar to thatillustrated in FIG. 11, where, however, an ancillary reinforcing element37 is applied. The composition forming the ancillary reinforcing elementis applied from fluid state by pouring. A flexible epoxy resincomposition illustrates a suitable material for this purpose. 26 and 32ahave the same meaning as in FIG. 11. Section 13 is the position wherethe cut is made for FIG. 13.

FIG. 13 is the same as FIG. 12 with the difference, that at position 13of FIG. 12 the tile has been cut and/or ground flat, thus producing thetile of FIG. 13.

FIG. 14 is the same as FIG. 11 with the difference, that at position 14of FIG. 11 the tile is.cut and/or ground flat, thus producing the tileof FIG. 14.

FIG. 15 is the tile of FIG. 14 with the additional feature that as anadditional layer of a prefabricated board 38 is applied as an ancillaryreinforcing element. The board may be cement board, plywood, chipboard,amongst others. 39 is an adhesive layer providing adhesion between theboard and the backing component.

FIG. 16 shows the cross-sectional view of a tile where the facingcomponent has been prepared in the mold of FIG. 2 with a backingcomponent 32a. The composition forming the backing component is appliedfrom fluid state. The rear surface of the backing component is cutand/or ground smooth. 26 is the facing component.

FIG. 17 shows the cross-sectional view of a tile with a facing componentpremolded in the mold of FIG. 2. 26 is the facing component. 32a is abacking component. The composition producing the backing component isapplied in a fluid state and does not fully fill the cavity formed bythe texture of the facing component. The remaining cavity jointly formedby the facing component and the backing component is then filled with arigid polyurethane foam 42 as an'ancillary reinforcing element. Therigid polyurethane foam is applied from a fluid state and isfoamed-in-place. The crest points of the rear surface of the facingcomponent and the rear surface of the foam are ground smooth, anadhesive 39 is applied and a board 38 is applied to the rear surface. Asan alternative to the product illustrated by FIG. 17, the joint cavitymay be left unfilled and theadhesive applied only to the crests of therear surface of the facing component. The board is applied as the laststep in both alternatives.

FIGS. 18 and 21 are planar views of the facing of two tiles with raisedscupltured effects of texture. In both figures, 26 is the facing, and 40is a protuberance indicating the raised scupltured texture of thefacing. 40 may have undercuts. Section 19 in FIG. 18 shows the positionof a cut taken for the cross-section illustrated by FIG. 19. Section 22in FIG. 21 shows the position of a cut taken for the cross-sectionillustrated by FIG. 22.

FIGS. 19 and 20 are two alternative cross-sections of tiles takenatposition 19 of FIG. 18. 26 is the facing component. 32a is the backingcomponent formed from a fluid state. 40 is the sculptured raised textureof the facing of the tile. In FIG. 20 39 is an adhesive layer and 38 isa board applied as an ancillary reinforcing element. It should be notedthat 40 is a part of 26.

FIGS. 22 and 23 are two alternative cross-sections of tiles taken atposition 22 of FIG. 21. 26 is the facing component. 32a is the backingcomponent formed from a fluid composition. In the protuberance area 40of the textured surface of the facing component a hollow 43 is formed ina discontinuous manner. 41 in FIG. 22 is the rear surface of the backingcomponent ground to a smooth surface. In FIG. 23 a board backing 38 isapplied as an ancillary reinforcing element with the aid of the adhesive39. In an alternative of either one of these two tiles the hollow cavity43 may be filled with a rigid polyurethane foam formed from a fluidcomposition by the foam-in-place method.

FIG. 24 is another example of a tile. 26 is the facing component. 32a isa backing component formed from a fluid composition. The facing andbacking component form a joint cavity. A rigid polyurethane foam 42fills out the said cavity.

In FIG. 7 33 is the same as in FIG. 6. In FIG. 8a 39 is an adhesive. Theuse of the adhesive is optional.

It should be noted that whereas FIG. 8 is a crosssectional view of FIG.7, the latter does not show the backing component 32a.

The election of the manufacturing method to be used for a particulartile of this invention depends on the materials chosen for thecomponents. This includes the election whether a supporting mold shouldbe present during the formation of the backing component.

Rigid foams have been discussed further above as rigidifying componentsof the herein claimed rigid tiles. One of the interesting embodiments ofrigid foams are polystyrene rigid foams. These are discussed in detailin my prior application Ser. No. 523,778, now U.S. Pat. No. 3,419,455,in my applications Ser. No. 760,415,

which has been continued by copending applications Ser. Nos. 141,181 and142,037 (now U.S. Pat. No. 3,703,571). Ser. No. 760,415 is acontinuation of U.S. Pat No. 3,419,455. Polystyrene rigid foams arediscussed in Ser. No. 141,181 under the heading of THE INNER RIGIDIFIERCOMPONENT, under the subtitle: (2) Polystyrene Rigid FoamszfEssentiallypolystyrene beads are used which contain volatile materials encapsulatedtherein. The latter cause foaming upon heating. The beads can bepartially pre-expanded. Polystyrene Rigid Foams are dealt with in detailin the book of T. H. Ferrigno, RIGID PLASTICS FOAMS, Reinhold PublishingCorporation, New York, N.Y. 1963., to which reference was made in mysaid earlier U.S. Pat. No. 3,419,455 and said copending applicationsSer. Nos. 141,481 and 142,037 (now U.S. Pat. 3,703,571).

One of the important embodiments of the herein claimed process is theutilization of a pliable plastics material comprising an acrylic monomerin a polymerized state. Acrylic monomers in a polymerized state arediscussed in this specification under the heading THE FACING COMPONENT"as Example-A, and under the heading THE FACING COMPONENT." Acrylics arediscussed in detail also under the heading ofTHE BACKING COMPONENT. Theyare also well known in the art. 9 v

As indicated above, molding of the facing component can be performed,for example, by calendering and embossing.

The facing components of the herein claimed tile have a wall thicknessof from about mils to about 250 mils. These limits are not arbitrary butare required by the success of the process. If the wall thickness ishigher than the'top limit, it is difficult to remove the facingcomponent from its mother mold. This difficulty is aggravated when themolded texture has several undercuts. On the other hand, if the wallthickness is too low, the facing component deforms or even wrinkleswhile the rigidifier backing component is applied and set. Suchdeformation cannot be prevented even in cases where a supporting mold ispresent during the application of the composition forming the backingcomponent. Reference is made to portions of my earlier patents andapplications wherein the wall thickness is discussed. As explained forexample in U.S. Pat. No. 3,414,456, the backing component (fleshportion) improves the resistance to cold flow or heat distortion. Also,the backing component rigidifies the shell component to reduceflexibility of the latter.-The skin materials protect the rigidifierflesh portion (backing component) from fracture. This mutual improvingeffect is synergistic. It is obvious that when the facing component istoo thin it cannot perform its intended function, such as preventing thefracturing of the backing component.

I claim:

1. The process of producing a rigid composite impact resistant texturedtile comprising a pliable and essentially void-free plastics facingcomponent and a rigid backing component, said process comprising thesequence of steps:

i. molding the facing component to have a textured front surface, a wallthickness of from about 15 /2 mils to about 250 mils and to have itsfinal physical and textural characteristics, said molding being carriedout in a manner to reproduce in positive form the negative texture ofits negative mother mold;

ii. compounding in a separate process step a solidifiable flowingplastic composition;

iii. depositing said separately compounded composition on the entirerear surface of said facing component;

iv. forming and rigidifying said flowing composition into a one piecerigid backing component behind the entire rear surface of said moldedfacing component;

steps (i) to (iv) producing a tile having a thickness of from aboutone-sixteenth of an inch to about 2 inches.

2. The process of producing a rigid composite impact resistanttexturally decorated tile comprising a pliable and essentially void-freeplastics facing component and j a rigid backing component integrallyadhering thereto,

said process comprising the steps of:

l. molding said facing component from a pliable plastics material tohave a textured and essentially void-free front surface and a wallthickness of from about l5 /zmils to about 250 mils, said molding .beingcarried out in a manner to reproduce in a positive form the negativetexture 'of its negative mother mold; ll. removing said molded facingcomponent from its mold;

III. compounding in a separate process step a solidifiable flow plasticcomposition;

IV. depositing said separately compounded composition on the entire rearsurface of said facing component;

V. forming and rigidifying said flowing composition to form the rigidbacking component behind the entire rear surface of said molded facingcomponent;

steps( I) to (V)'producing a tile having a thickness of from aboutone-sixteenth of an inch to about 2 inches.

3. The process of providing a rigid composite impact resistanttexturally decorated tile comprising a pliable and essentially void-freeplastics facing component and a rigid backing component integrallyadhered thereto, said process comprising the steps of:

a. molding said facing component to have a textured front surface, awall thickness of from about 15% mils to about 250 mils, and side wallsdefining a molding cavity, said molding carried out in a manner toreproduce in positive form the negative texture of its negative mothermold;

b. removing said molded facing component from its mold;

c. compounding in a separate process step a solidifiable liquidseparately compounding a solidifiable liquid plastic composition;

d. depositing said separately compounded composition in said mold cavityto cover the entire rear surface of said facing component, said facingcomponent serving as a mold for said solidifiable liquid composition;and

e. forming and rigidifying said liquid plastic composition to form saidrigid backing component behind the entire rear surface of said facingcomponent;

steps (a) through (c) producing a tile having a thickness of from aboutone-sixteenth of an inch to about 2 inches.

4. The proces of claim 1, wherein the facing component is formed from adispersion of a vinyl polymer in a liquid plasticizer, said polymercomprising vinyl chloride in a polymerized state and the molding of thefacing component is carried out by a casting operation.

5. The process of claim 1, wherein the solidifiable flowing plasticcomposition applied to the rear surface of the facing componentcomprises a fiberglass reinforced rigid polyester resin. 7

6. The process of claim 1, wherein the solidifiable flowing plasticcomposition comprises a rigid polyester resin composition.

7. The process of claim 1, wherein the solidifiable flowing plasticcomposition is a foam composition which becomes rigid upon foaming andcuring.

'8. The process of claim 1, wherein the solidifiable flowing plasticcomposition forming the rigid backing component comprises a latex andfillers in proportions to yield after solidification a backing componentcontaining at least 200 weight parts of fillers for each 100 weightparts of elastomer solids.

9. The process of claim 1, wherein the solidifiable flowing plasticcomposition forming the rigid backing component comprises plaster ofparis.

10. The process of claim 1, wherein the solidifiable flowing plasticcomposition forming the rigid backing component comprises asphalt.

11. The process of claim 1, wherein the facing component is molded froma thermoplastic plastics sheet- 12. The proces of claim 1, wherein asupporting mold is used during step (IV).

13. The process of claim 1, wherein the facing component is molded bycalendering and embossing.

14. The process of claim 2, wherein in step (I) the pliable plasticsmaterial comprises an acrylic monomer in a polymerized state.

15. The process of claim 1, wherein the flowing composition isrigidified in (iv) at ambient temperature.

16. The process of producing a rigid composite impact resistant texturedtile comprising a pliable and essentially voidfree plastics facingcomponent and a rigid backing component, said process comprising thesequence of steps:

i. molding the facing component to have a textured front surface, a wallthickness of from about 15 /2 mils to about 250 mils and to have itsfinal physical and textural characteristics, said molding being carriedout in a manner to reproduce in positive form the negative texture ofits negative mother mold;

ii. separately compounding flowing foam forming polystyrene beads;

iii. depositing said separately compounded composition on the rearsurface of said facing component;

iv. heating the polystyrene beads to cause them to foam-in-place incontact with the entire rear surface of said facing component;

v. forming and rigidifying the resulting cellular structure into aone-piece rigid backing component behind the entire rear surface of saidmolded facing component;

vi. recovering the rigid composite article of manufacture so produced;steps (i) to (vi) being carried-out in a manner to produce a tile havinga thickness from about onesixteenth of an inch to about 2 inches andrigidifying the facing component in its entirety while preventing thedeformation of the facing component.

i 17. The process of claim 16, wherein the polystyrene beads of (ii) areunexpanded.

18. The process of claim 16, wherein the polystyrene beds of (ii) arepartially expanded.

19. The process of claim 16, wherein the completion of the steps (i) to(vi) prevents the deformation of the facing component by hand pressure.

20. The process of claim 1, wherein the solidifiable flowing plasticcompositon applied to the rear surface of the facing component comprisesa fiberglass reinforced rigid epoxy resin.

21. The process of claim 1, wherein the solidifiable flowing plasticcomposition comprises a rigid epoxy resin composition.

22. The process of claim 1, wherein an additional process step aprefabricated board is adherently at tached to the rear surface of thebacking component as an ancillary reinforcing element.

2. The process of producing a rigid composite impact resistanttexturally decorated tile comprising a pliable and essentially void-freeplastics facing component and a rigid backing component integrallyadhering thereto, said process comprising the steps of: I. molding saidfacing component from a pliable plastics material to have a textured andessentially void-free front surface and a wall thickness of from about15 1/2 mils to about 250 mils, said molding being carried out in amanner to reproduce in a positive form the negative texture of itsnegative mother mold; II. removing said molded facing component from itsmold; III. compounding in a separate process step a solidifiable flowplastic composition; IV. depositing said separately compoundedcomposition on the entire rear surface of said facing component; V.forming and rigidifying said flowing composition to form the rigidbacking component behind the entire rear surface of said molded facingcomponent; steps (I) to (V) producing a tile having a thickness of fromabout one-sixteenth of an inch to about 2 inches.
 3. The process ofproviding a rigid composite impact resistant texturally decorated tilecomprising a pliable and essentially void-free plastics facing componentand a rigid backing component integrally adhered thereto, said processcomprising the steps of: a. molding said facing component to have atextured front surface, a wall thickness of from about 15 1/2 mils toabout 250 mils, and side walls defining a molding cavity, said moldingcarried out in a manner to reproduce in positive form the negativetexture of its negative mother mold; b. removing said molded facingcomponent from its mold; c. compounding in a separate process step asolidifiable liquid separately compounding a solidifiable liquid plasticcomposition; d. depositing said separately compounded composition insaid mold cavity to cover the entire rear surface of said facingcomponent, said facing component serving as a mold for said solidifiableliquid compositIon; and e. forming and rigidifying said liquid plasticcomposition to form said rigid backing component behind the entire rearsurface of said facing component; steps (a) through (e) producing a tilehaving a thickness of from about one-sixteenth of an inch to about 2inches.
 4. The proces of claim 1, wherein the facing component is formedfrom a dispersion of a vinyl polymer in a liquid plasticizer, saidpolymer comprising vinyl chloride in a polymerized state and the moldingof the facing component is carried out by a casting operation.
 5. Theprocess of claim 1, wherein the solidifiable flowing plastic compositionapplied to the rear surface of the facing component comprises afiberglass reinforced rigid polyester resin.
 6. The process of claim 1,wherein the solidifiable flowing plastic composition comprises a rigidpolyester resin composition.
 7. The process of claim 1, wherein thesolidifiable flowing plastic composition is a foam composition whichbecomes rigid upon foaming and curing.
 8. The process of claim 1,wherein the solidifiable flowing plastic composition forming the rigidbacking component comprises a latex and fillers in proportions to yieldafter solidification a backing component containing at least 200 weightparts of fillers for each 100 weight parts of elastomer solids.
 9. Theprocess of claim 1, wherein the solidifiable flowing plastic compositionforming the rigid backing component comprises plaster of paris.
 10. Theprocess of claim 1, wherein the solidifiable flowing plastic compositionforming the rigid backing component comprises asphalt.
 11. The processof claim 1, wherein the facing component is molded from a thermoplasticplastics sheeting.
 12. The proces of claim 1, wherein a supporting moldis used during step (IV).
 13. The process of claim 1, wherein the facingcomponent is molded by calendering and embossing.
 14. The process ofclaim 2, wherein in step (I) the pliable plastics material comprises anacrylic monomer in a polymerized state.
 15. The process of claim 1,wherein the flowing composition is rigidified in (iv) at ambienttemperature.
 16. The process of producing a rigid composite impactresistant textured tile comprising a pliable and essentially void-freeplastics facing component and a rigid backing component, said processcomprising the sequence of steps: i. molding the facing component tohave a textured front surface, a wall thickness of from about 15 1/2mils to about 250 mils and to have its final physical and texturalcharacteristics, said molding being carried out in a manner to reproducein positive form the negative texture of its negative mother mold; ii.separately compounding flowing foam forming polystyrene beads; iii.depositing said separately compounded composition on the rear surface ofsaid facing component; iv. heating the polystyrene beads to cause themto foam-in-place in contact with the entire rear surface of said facingcomponent; v. forming and rigidifying the resulting cellular structureinto a one-piece rigid backing component behind the entire rear surfaceof said molded facing component; vi. recovering the rigid compositearticle of manufacture so produced; steps (i) to (vi) being carried outin a manner to produce a tile having a thickness from aboutone-sixteenth of an inch to about 2 inches and rigidifying the facingcomponent in its entirety while preventing the deformation of the facingcomponent.
 17. The process of claim 16, wherein the polystyrene beads of(ii) are unexpanded.
 18. The process of claim 16, wherein thepolystyrene beds of (ii) are partially expanded.
 19. The process ofclaim 16, wherein the completion of the steps (i) to (vi) prevents thedeformation of the facing component by hand pressure.
 20. The process ofclaim 1, wherein the solidifiable flowing plastic compositon applied tothe rear surface of the facing component comprises a fiberglassReinforced rigid epoxy resin.
 21. The process of claim 1, wherein thesolidifiable flowing plastic composition comprises a rigid epoxy resincomposition.
 22. The process of claim 1, wherein an additional processstep a prefabricated board is adherently attached to the rear surface ofthe backing component as an ancillary reinforcing element.